Crack monitoring method based on Cu coating sensor and electrical potential technique for metal structure

Advanced crack monitoring technique is the cornerstone of aircraft structural health monitoring. To achieve real-time crack monitoring of aircraft metal structures in the course of service, a new crack monitoring method is proposed based on Cu coating sensor and electrical potential difference principle. Firstly, insulation treatment process was used to prepare a dielectric layer on structural substrate, such as an anodizing layer on 2A12-T4 aluminum alloy substrate, and then a Cu coating crack monitoring sensor was deposited on the structure fatigue critical parts by pulsed bias arc ion plating technology. Secondly, the damage consistency of the Cu coating sensor and 2A12-T4 aluminum alloy substrate was investigated by static tensile experiment and fatigue test. The results show that strain values of the coating sensor and the 2A12-T4 aluminum alloy substrate measured by strain gauges are highly coincident in static tensile experiment and the sensor has excellent fatigue damage consistency with the substrate. Thirdly, the fatigue performance discrepancy between samples with the coating sensor and original samples was investigated. The result shows that there is no obvious negative influence on the fatigue performance of the 2A12-T4 aluminum alloy after preparing the Cu coating sensor on its surface. Finally, crack monitoring experiment was carried out with the Cu coating sensor. The experimental results indicate that the sensor is sensitive to crack, and crack origination and propagation can be monitored effectively through analyzing the change of electrical potential values of the coating sensor.